How to Make Aluminum Cast Parts
Aluminum casting is the process of pouring molten aluminum into a mold to create a part of a desired shape. Casting is used in many different industries to create a wide range of parts. Aluminum is a lightweight yet strong metal with excellent corrosion resistance. The amateur hobbyist can create aluminum castings with the right tools, instructions and safety precautions.
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Things You'll Need
- Polystyrene foam
- Knife
- Hot glue (optional)
- Sheetrock mud
- Casting flask
- Casting sand
- Tamping rod
- Metal rod
- Trowel
- Casting pressure tool
- Scrap aluminum
- Crucible
- Wire brush
- Grinder
Instructions
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1
Create a model of the part to be cast using the polystyrene foam and knife. Composite shapes can be created by cutting individual shapes and adhering them together with hot glue. Add a pouring sprue shape to the top of the part.
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2
Coat the polystyrene with a layer of sheetrock mud. This will provide a smoother surface finish than the polystyrene alone.
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3
Pack some sand into the casting flask. Place the polystyrene part into the flask, and pack casting sand around the part, using the tamping rod to compact the sand around the part. Use a metal rod to create a vent channel to the polystyrene.
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4
Continue to pack the sand around the part until the sand is flush with the top of the sprue. Remove the metal rod from the sand. Place the casting pressure tool around the sprue to allow the aluminum to pool.
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Add the scrap aluminum to the crucible. Heat the crucible and allow the aluminum to melt.
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Pour the molten aluminum into the sprue. The aluminum will melt the foam and fill the void in the sand. The vent will allow gas to escape.
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7
Allow the aluminum to cool for several minutes. Dig the sand away from the part and remove the aluminum casting from the sand. The aluminum will still be quite hot.
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Use a wire brush to remove any sand or drywall mud from the surface of the part. Excess aluminum can be ground or cut away, and the surface can be smoothed if desired.
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Tips & Warnings
Aluminum casting is a dangerous activity that requires specific equipment and processes. Consult an expert before attempting to cast on your own. Always wear protective equipment when handling hot metal, including gloves and a face shield.
